Tubular drive system

ABSTRACT

Present embodiments are directed to tubular drive system including a gripping device configured to couple with a length of tubular, a rotational system configured to drive rotation of the gripping device, and a load support feature coupled to the gripping device and the rotational system, wherein the load support feature is configured to support the gripping device and the rotational system.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/011,964, entitled “TUBULAR DRIVE SYSTEM,” filed Jun. 13, 2014, which is hereby incorporated by reference in its entirety.

BACKGROUND

Present embodiments relate generally to the field of drilling and processing of wells, and, more particularly, to a top drive system for coupling with, rotating, and releasing drillpipe elements to facilitate insertion and removal of the drillpipe elements into and out of a wellbore during drilling operations and the like.

In conventional oil and gas operations, a drilling rig is used to drill a wellbore to a desired depth using a drill string, which includes drillpipe, drill collars and a bottom hole drilling assembly. During drilling, the drill string may be turned by a rotary table and kelly assembly or by a top drive to facilitate the act of drilling. As the drill string progresses down hole, additional drillpipe is added to the drill string. When a top drive is used in such operations, the drillpipe or drill string generally couples with a rotatable cylindrical stem of the top drive that may be referred to as the quill. More specifically, the drillpipe or drill string couples with the quill via a top drive sub that threadably couples with the quill and the drillpipe or drill string. The sub may function to limit wear on the quill.

It is now recognized that certain aspects of existing drilling techniques are inefficient and cumbersome because of limitations on other procedural components during certain phases of operation.

BRIEF DESCRIPTION

In accordance with one aspect of the disclosure, a tubular drive system includes a gripping device configured to couple with a length of tubular, a rotational system configured to drive rotation of the gripping device, and a load support feature coupled to the gripping device and the rotational system and configured to support the gripping device and the rotational system.

In accordance with another aspect of the disclosure, a method includes gripping a distal end of a length of tubular with a gripping device; driving rotation a gear fixed to the gripping device with at least one motor; and coupling the length of tubular to a drill string stump, wherein the gripping device and the at least one motor are supported by a load plate.

In accordance with a further embodiment of the disclosure, a system includes a gripping device configured to couple with a distal end of a length of tubular, a rotational system comprising a plurality of motors configured to drive rotation of a gear fixed to the gripping device, a load plate coupled to the gripping device and the rotational system and configured to support the gripping device and the rotational system, and a thrust bearing disposed between the gripping device and the load plate, wherein the thrust bearing is configured to transfer a load from the gripping device to the load plate.

DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 is a schematic of a well being drilled in accordance with present techniques;

FIG. 2 is a perspective view of a tubular drive system, in accordance with present techniques;

FIG. 3 is a cross-sectional side view of a tubular drive system, in accordance with present techniques; and

FIG. 4 is a cross-sectional side view of a tubular drive system, in accordance with present techniques.

DETAILED DESCRIPTION

Present embodiments are directed to a system for facilitating assembly and disassembly of tubular (e.g., drill pipe elements). For example, present embodiments include a tubular drive system having a gripping device and a rotational system supported by a load plate that is suspended by yoke links and a yoke from a traveling block or other component of a drilling rig. The gripping/lifting system may include features configured to engage and lift a length of tubular (e.g., a drill pipe element) and align the length of tubular with a drill string. In certain embodiments, the gripping device may include components configured to grip, seal, and engage with the length of tubular without creating a threaded connection between the gripping device and the length of tubular. Once the tubular drive system positions the length of tubular above the drill string, the rotational system may drive rotation of the gripping device, and thus drive rotation of the length of tubular. In this manner, the tubular drive system may add the length of tubular to the drill string. The gripping device and the rotational drive system may similarly function to grip and remove (e.g., unthread) a length of tubular from the drill string to disassemble the drill string. As will be appreciated, the disclosed embodiments may not include components such as a quill, grabber legs, and so forth, which would add to the total overall length of the tubular drive system. As a result, the tubular drive system may have a shorter overall length as compared to traditional top drive systems, which may improve the operation and functionality of the tubular drive system in accordance with present embodiments.

Turning now to the drawings, FIG. 1 is a schematic of a drilling rig 10 in the process of drilling a well in accordance with present techniques. The drilling rig 10 features an elevated rig floor 12 and a derrick 14 extending above the rig floor 12. A supply reel 16 supplies drilling line 18 to a crown block 20 and traveling block 22 configured to hoist various types of drilling equipment above the rig floor 12. The drilling line 18 is secured to a deadline tiedown anchor 24, and a drawworks 26 regulates the amount of drilling line 18 in use and, consequently, the height of the traveling block 22 at a given moment. Below the rig floor 12, a drill string 28 extends downward into a wellbore 30 and is held stationary with respect to the rig floor 12 by a rotary table 32 and slips 34 (e.g., power slips). A portion of the drill string 28 extends above the rig floor 12, forming a stump 36 to which another length of tubular 38 (e.g., a joint of drill pipe) may be added.

A tubular drive system 40 (e.g., a top drive system) in accordance with present embodiments, hoisted by the traveling block 22, positions the tubular 38 above the wellbore 30. In the illustrated embodiment, the tubular drive system 40 includes a gripping device 42 and a rotational system 44. The gripping device 42 of the tubular drive system 40 is engaged with a distal end 46 (e.g., box end) of the tubular 38. The tubular drive system 40, once coupled with the tubular 38, may then be utilized to lower the coupled tubular 38 toward the stump 36, and the rotational system 44 may rotate the gripping device 42 and the tubular 38 such that the tubular 38 connects with the stump 36 and becomes part of the drill string 28. In present embodiments, the tubular drive system 40 may not include a quill, a sub, and/or other components which would add to a total length of the tubular drive system 40. As a result, the tubular drive system 40 may have a shorter overall length than traditional top drive systems, thereby improving and simplifying the functionality and operation of the tubular drive system 40.

FIG. 2 is a perspective view of an embodiment of the tubular drive system 40, including the gripping device 42 and the rotational system 44. In certain embodiments, the gripping device 42 may be a system similar to the systems (e.g., gripping devices) described in U.S. Patent Application No. 13/655,798, which is published as U.S. Patent Application Publication No. 20130168106, and which is hereby incorporated by reference in its entirety. The gripping device 42 and the rotational system 44 are supported by a load plate 50 (e.g., a load bearing body, load frame, or other load support feature) of the tubular drive system 40. The weight and torque acting on the gripping device 42 and the rotational system 44 are transferred to the drilling rig 10 via yoke links 52 and a yoke 54 coupled to the load plate 50. The weight and torque acting on the gripping device 42 and the rotational system 44 may also be transferred to the drilling rig 10 by a torque restrained device (e.g., a torque track system), which is not shown in FIG. 2. As shown, the load plate 50, the yoke links 52, and the yoke 54 are coupled to one another via pivotable connections 56 to enable rotation and/or pivoting of the components relative to one another. In certain embodiments, the yoke 54 may couple to hooks or another component coupled to the traveling block 22 of the drilling rig 10. As a result, the tubular drive system 40 may grip the length of tubular 38, and the traveling block 22, drawworks 26, and other components may be used to raise and lower the tubular drive system 40 and tubular 38, as desired.

In the illustrated embodiment, the rotational system 44 includes four motors 58 supported by the load plate 50. However, other embodiments may include other numbers of motors 58, such as 1, 2, 3, 5, 6, or more motors 58. For example, the motors 58 may be hydraulic motors, electric motors, or other suitable types of motors configured to generate and apply a rotational force. As described in detail below, the motors 58 are configured to drive rotation of a transmission (e.g., transmission 112 shown in FIG. 3) coupled to the gripping device 42. In this manner, the gripping device 42 and the tubular 38 gripped and supported by the gripping device 42 may be rotated during assembly and/or disassembly of the drill string 28.

FIG. 3 is a cross-sectional side view of an embodiment of the tubular drive system 40. As mentioned above, the tubular drive system 40 includes the gripping device 42 and the rotational system 44, which are both supported by the load plate 50 of the tubular drive system 40. In the illustrated embodiment, the gripping device 42 is disposed generally above the load plate 50. Weight and torque acting on the gripping device 42 are transferred to the load plate 50 via a thrust bearing 100 disposed between a body 102 of the gripping device 42 and the load plate 50. Additionally, a centralizer bearing 104 is disposed between the load plate 50 and the body 102 of the gripping device 42 to enable and improve alignment of the gripping device 42 within the load plate 50. In other words, the centralizer bearing 104 and the thrust bearing 100 may cooperatively align the gripping device 42 along a vertical axis 105 to keep the gripping device 42 and the tubular 38 supported by the gripping device 42 in a vertical orientation.

As mentioned above, the gripping device 42 may be similar to the systems (e.g., gripping devices) described in U.S. Patent Application No. 13/655,798, which is published as U.S. Patent Application Publication No. 20130168106, and which is hereby incorporated by reference in its entirety. The gripping device 42 may include various pipe or tubular 38 gripping features and a hydraulically energized piston 106 that moves with the gripping device 42 and seals against the tubular 38. For example, in the illustrated embodiment, the gripping device 42 includes elevators 108 and torsional clamping actuators 110 (e.g., torsional clamp devices). These features operatively cooperate to facilitate surrounding the distal end 46 of the tubular 38, vertically securing the tubular 38 within the gripping device 42, creating a sealed engagement between the gripping device 42 and the tubular 38, centralizing the tubular 38 within the gripping device 42, and applying torque to the tubular 38 via the gripping device 42.

The rotational system 44 of the tubular drive system 40 includes a transmission 112 configured to transfer rotational forces generated by the motors 58 to the gripping device 42. The transmission 112 includes a main gear 114, which is fixedly attached to the main body 102 of the gripping device 42, as indicated by arrows 116. For example, the main gear 114 may be bolted, welded, brazed, threaded, or otherwise mechanically coupled to the main body 102 of the gripping device 42. Rotational forces generated by the motors 58 may be transferred to the main gear 114 by belts, chains, teeth, cogs, helical surfaces, beveled surfaces, crown surfaces, worm gears, and/or other suitable connections configured to transfer rotational movement.

FIG. 4 is a cross-sectional side view of another embodiment of the tubular drive system 40. The illustrated embodiment includes similar elements and element numbers as the embodiment shown in FIG. 3. In the illustrated embodiment, the gripping device 42 is supported by the load plate 50 near a top of the gripping device 42. That is, an upper end 120 of the main body 102 of the gripping device 42 includes a flange 122 that engages with the thrust bearing 100 of the tubular drive system 40. Weight and torque acting on the gripping device 42 may be transferred from the main body 102 to the thrust bearing 100 and further to the load plate 50 of the tubular drive system 40.

During a process of installing or removing lengths of tubular 38, it may be desirable to circulate fluids (e.g., drilling mud) through the drill string 28. Operation of the gripping device 42 may include gripping an outer portion of the tubular 38 with the elevators 108 and/or torsional clamping actuators 110 rather than attaching a sub via threaded engagement. For example, the upper distal end 46 of the tubular 38 being added may be gripped around its outer perimeter with the gripping device 42 without making-up an extension of the tubular drive system 40 to threads of the distal end 46 such that more rapid positioning of the drillpipe element is facilitated. This may result in difficulty flowing fluids from the tubular drive system 40 through the tubular 38 being added or the drill string 28 during certain phases of the process.

To enable fluid (e.g., drilling mud) circulation through the tubular drive system 40, the tubular 38, and the drill string 28, the tubular drive system 40 includes a variety of fluid flow components and associated sealing elements and/or sealing features. For example, the tubular drive system 40 includes a gooseneck connection 124 and a washpipe 126, which may receive a flow of fluid and direct the flow of fluid through the hydraulically energized piston 106 and into the tubular 38. The tubular drive system 40 also includes various seals to block fluid from exiting the flow path through the gooseneck connection 124, the washpipe 126, the hydraulically energized piston 106, and the tubular 38. For example, the tubular drive system 40 includes a rotary seal 128 disposed between the washpipe 126 and an outer shell 130 surrounding the washpipe 126. The tubular drive system 40 also includes an upper seal 132 disposed between the hydraulically energized piston 106 and the main body 102 of the gripping device 42 and a lower seal 134 configured to be disposed between the hydraulically energized piston 106 and the tubular 38. The seals 128, 132, and 134 enable proper circulation of fluids during certain portions of the drill string 28 assembly and/or disassembly process. That is, present embodiments are directed to providing a seal between the tubular drive system 40 and the tubular 38 such that fluid can efficiently pass from the tubular drive system 40 into the drillpipe element or tubular 38.

In certain embodiments, the tubular drive system 40 may include other features, such as one or more control features. For example, the tubular drive system 40 may include a controller configured to regulate operation of the gripping device 42, the rotational system 44 (e.g., the motors 58), the elevators 108, the torsional clamping actuators 110, and/or other components of the tubular drive system 40. Additionally, the tubular drive system 40 may include sensors configured to detect one or more operating parameters of one or more components of the tubular drive system 40. The one or more operating parameters may be used as feedback by the controller, and the controller may further control operation of one or more components of the tubular drive system 40 based on the feedback (e.g., the operating parameters measured by the sensors).

As discussed in detail above, present embodiments are directed towards a tubular drive system 40 having the gripping device 42 and the rotational system 44 which are supported by the load plate 50. The load plate 50 is suspended by yoke links 52 and the yoke 54 from the traveling block 22 or other component of the drilling rig 10. As discussed above, the gripping system 42 may include features configured to engage and lift the tubular 38 and align the tubular 38 with the stump 36 of the drill string 28. For example, the gripping device 42 may include components, such as elevators 108 and or torsional clamping actuators 110, configured to grip, seal, and engage with the length of tubular 38 without creating a threaded connection between the gripping device 42 and the length of tubular 38. Once the tubular drive system 40 positions the length of tubular 38 above the drill string 28, the rotational system 44 may drive rotation of the gripping device 42, and thus drive rotation of the length of tubular 38. In this manner, the tubular drive system 40 may add the length of tubular 38 to the drill string 28. Furthermore, the gripping device 42 and the rotational system 44 may similarly function to grip and remove (e.g., unthread) the tubular 38 from the drill string 28 to disassemble the drill string 28. As discussed above, the disclosed embodiments may not include components such as a quill, grabber legs, and so forth, which may add to the total overall length of the tubular drive system 40. As a result, the tubular drive system 40 may have a shorter overall length as compared to traditional top drive systems, which may improve the operation and functionality of the tubular drive system 40.

While only certain features of the present disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the present disclosure. 

1. A tubular drive system, comprising: a gripping device configured to couple with a length of tubular; a rotational system configured to drive rotation of the gripping device; and a load support feature coupled to the gripping device and the rotational system and configured to support the gripping device and the rotational system.
 2. The tubular drive system of claim 1, wherein the gripping device comprises: a main body configured to extend over and at least partially around a distal end of the length of tubular; torsional clamp devices configured to engage an outer circumferential surface of the length of tubular with frictional engagement features that extend radially inward from the main body; and at least one seal configured to engage with the distal end of the length of tubular and facilitate fluid flow through the gripping device into the length of tubular.
 3. The tubular drive system of claim 1, wherein the gripping device comprises elevators configured to radially engage an outer circumferential area of the length of tubular to establish support for a pulling load without establishing a threaded engagement with threads of the length of tubular.
 4. The tubular drive system of claim 1, wherein the rotational system comprises: at least one motor configured to generate a rotational force; and a transmission configured to transfer the rotational force to the gripping device.
 5. The tubular drive system of claim 4, wherein transmission comprises a gear fixed to a main body of the gripping device.
 6. The tubular drive system of claim 5, wherein the gear is fixed to the main body of the gripping device by bolting, welding, brazing, threading, or any combination thereof.
 7. The tubular drive system of claim 4, wherein the at least one motor comprises a hydraulic motor, an electric motor, or a combination thereof.
 8. The tubular drive system of claim 1, comprising a plurality of yoke links coupled to the load support feature and configured to transfer weight from the load support feature to a traveling block.
 9. The tubular drive system of claim 8, wherein each of the plurality of yoke links are coupled to the load support feature via a respective pivotable connection.
 10. The tubular drive system of claim 1, comprising a thrust bearing disposed between the gripping device and the load support feature, wherein the thrust bearing is arranged within the drive system to transfer a weight of the gripping device and of the length of tubular to the load support feature.
 11. The tubular drive system of claim 1, comprising a centralizer bearing disposed between the gripping device and the load support feature, wherein the centralizer bearing is configured to maintain a vertical alignment of the gripping device relative to the load support feature.
 12. The system of claim 1, comprising a control feature configured to monitor operational parameters of the gripping device.
 13. A method, comprising: gripping a distal end of a length of tubular with a gripping device; driving rotation a gear fixed to the gripping device with at least one motor; and coupling the length of tubular to a drill string stump, wherein the gripping device and the at least one motor are supported by a load plate.
 14. The method of claim 13, comprising transferring a load from the gripping device to the load plate with a thrust bearing disposed between the gripping device and the load plate.
 15. The method of claim 13, comprising transferring a load from the load plate to a traveling block with a plurality of yoke links pivotably coupled to the load plate.
 16. The method of claim 13, wherein gripping the distal end of the length of tubular with the gripping device comprises radially engaging an outer circumference of the distal end of the length of tubular with a plurality of elevators of the gripping device without establishing a threaded engagement with threads of the length of tubular.
 17. The method of claim 13, wherein gripping the distal end of the length of tubular with the gripping device comprises positioning a seal against the distal end of the length of tubular to facilitate fluid flow through the gripping device into the length of tubular.
 18. A system, comprising: a gripping device configured to couple with a distal end of a length of tubular; a rotational system comprising a plurality of motors configured to drive rotation of a gear fixed to the gripping device; a load plate coupled to the gripping device and the rotational system and configured to support the gripping device and the rotational system; and a thrust bearing disposed between the gripping device and the load plate, wherein the thrust bearing is configured to transfer a load from the gripping device to the load plate.
 19. The system of claim 18, wherein the gripping device comprises a plurality of elevators configured to radially engage an outer circumference of the length of tubular to grip the length of tubular without establishing a threaded engagement with threads of the length of tubular.
 20. The system of claim 18, wherein the plurality of motors comprises four motors, each of the four motors comprises an electric motor or a hydraulic motor, and each of the four motors is configured to drive rotation of the gear fixed to the gripping device. 